FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arctic Cat 700 Diesel SD ATV. The complete manual is designed to aid service personnel in service-oriented applications. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying the complete manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display specific symbols to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.
© 2011 Arctic Cat Inc. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
July 2011
TABLE OF CONTENTS
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Service S erv ervice rvice M Manual anual
General Information ...................................................... 2 General Specifications................................................ 2 Torque Specifications ................................................. 2 Torque Conversions (ft-lb/N-m)................................... 4 Break-In Procedure .................................................... 4 Fuel - Oil - Lubricant................................................... 4 Genuine Parts............................................................. 5 Preparation For Storage ............................................. 5 Preparation After Storage........................................... 5 Periodic Maintenance/Tune-Up .................................... 7 Periodic Maintenance Chart ....................................... 7 Air Filter ...................................................................... 8 Valve Clearance ......................................................... 9 Muffler/Spark Arrester ................................................ 9 Adjusting Throttle Cable ............................................. 9 Engine RPM (Idle) .................................................... 10 Engine Oil - Filter...................................................... 10 Transmission Lubricant............................................. 11 Front Differential/Rear Drive Lubricant ..................... 11 Tires ......................................................................... 12 Driveshaft/Coupling .................................................. 12 Injector Timing .......................................................... 12 Lights ........................................................................ 12 Shift Lever ................................................................ 13 Frame/Welds/Racks ................................................. 14 Hydraulic Brake Systems ......................................... 14 Burnishing Brake Pads ............................................. 15 Coolant ..................................................................... 16 Checking/Replacing V-Belt ....................................... 16 Fuel Filter.................................................................. 18 Engine/Transmission .................................................. 19 Removing Engine/Transmission ............................... 20 Top-Side Components .............................................. 24 Left-Side Components.............................................. 52 Right-Side Components ........................................... 58 Center Components ................................................. 73 Installing Engine/Transmission ................................. 86 Troubleshooting ........................................................ 92 Fuel/Lubrication/Cooling............................................ 94 Diesel Fuel Injection System .................................... 94 Lift Pump .................................................................. 94 Unit Injectors............................................................. 95 Injector Timing .......................................................... 95 Fuel Filter.................................................................. 95 Fuel Solenoid Assembly ........................................... 95 Fuel Tank .................................................................. 96 Fuel/Vent Hoses ....................................................... 96 Oil Filter/Oil Pump .................................................... 96 Testing Oil Pump Pressure ....................................... 97 Liquid Cooling System.............................................. 97 Radiator .................................................................... 97 Hoses/Thermostat .................................................... 98 Fan ........................................................................... 99 Water Pump.............................................................. 99 Troubleshooting ........................................................ 99 Electrical System ...................................................... 100 Battery .................................................................... 100 Testing Electrical Components ............................... 101 Switches ................................................................. 101
700 DIESEL SD
A V
Accessory Receptacle/Connector.......................... 101 Brakelight Switch (Auxiliary)................................... 101 Brakelight Switch (Handlebar Control) ................... 102 Cooling Fan Switch ................................................ 102 Engine Coolant Temperature (ECT) Switch/ Thermistor ........................................................... 103 Glow Plug Controller/Relay .................................... 103 Fan Motor............................................................... 104 Fuse Block/Power Distribution Module................... 104 Speed Sensor ........................................................ 105 Ignition Switch ........................................................ 105 Handlebar Control Switches .................................. 106 Drive Select Switch ................................................ 106 Front Drive/Differential Lock Actuator .................... 107 Starter/Starter Solenoid ......................................... 107 Starter Relay .......................................................... 108 Alternator/Regulator............................................... 108 Headlights .............................................................. 109 Taillight - Brakelight ................................................ 110 Fuel Solenoid ......................................................... 110 Troubleshooting...................................................... 111 Drive System/Brake System..................................... 112 Front Drive Actuator ............................................... 112 Front Differential..................................................... 113 Drive Axles ............................................................. 126 Rear Gear Case ..................................................... 128 Hub ........................................................................ 129 Hydraulic Brake Caliper ......................................... 130 Troubleshooting Drive System ............................... 133 Troubleshooting Brake System .............................. 134 Suspension................................................................ 135 Shock Absorbers.................................................... 135 Front A-Arms.......................................................... 136 Rear A-Arms .......................................................... 138 Wheels and Tires ................................................... 139 Troubleshooting...................................................... 141 Steering/Frame/Controls .......................................... 142 Steering Post/Tie Rods .......................................... 142 Handlebar Grip....................................................... 144 Hand Brake Lever/Master Cylinder Assembly........ 144 Throttle Control ...................................................... 145 Shift Lever .............................................................. 146 LCD Gauge ............................................................ 146 Steering Knuckles .................................................. 147 Measuring/Adjusting Toe-In ................................... 148 Front Rack.............................................................. 150 Front Bumper Assembly......................................... 150 Front Body Panel/Side Panels................................ 150 Footrests ................................................................ 153 Belly Panel ............................................................. 153 Exhaust System ..................................................... 153 Rear Body Panel/Rack ........................................... 154 Adjusting Headlight ................................................ 155 Taillight Assembly................................................... 155 Seat........................................................................ 155 Troubleshooting...................................................... 156
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General Information NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.
General Specifications FUEL INJECTION Type Lombardini Unit Injectors Idle RPM (engine warm) 800-900 Throttle Cable Free-Play (at lever) 1/4 in. ELECTRICAL Glow Plug Type Lombardini Alternator Denso 12V/40 Amp CHASSIS Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) MISCELLANY Fuel Tank Capacity 20.81 L (5.5 U.S. gal.) Coolant Capacity 5.6 L (5.9 U.S. qt) Front Differential Capacity 275 ml (9.3 fl oz)* Rear Drive Capacity 250 ml (8.5 fl oz)* Engine Oil Capacity (with filter) 2.0 L (2.1 U.S. qt) Engine Oil Capacity (without filter) 1.9 L (2.0 U.S. qt) Transmission Capacity 600 ml (20.3 fl oz) Fuel (recommended) Biodiesel Blend up to 20% (B20)/42-50 Cetane Diesel #1 or #2/JP 5 or JP 8 Turbine Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Transmission Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 31.25 mm (1.23 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/27W (2) VALVES AND GUIDES Valve Face Diameter (intake) 34.4 mm (1.35 in.) (exhaust) 30.2 mm (1.19 in.) Valve Clearance (intake/exhaust) 0.20 mm (0.008 in.) (cold engine) Valve Guide/Stem Clearance 0.015-0.060 mm (0.0006-0.0024 in.) Valve Guide Inside Diameter 7.005-7.020 mm (0.2758-0.2764 in.) Valve Stem Diameter 6.960-6.990 mm (0.2740-0.2752 in.) Valve Face/Seat Width (intake/exhaust) 1.6-2.0 mm (0.063-0.079 in.) Valve Spring Free Length (min) 43.0 mm (1.69 in.)
Specifications subject to change without notice. * Visible at plug threads.
2
CYLINDER, PISTON, AND RINGS 75 x 77.6 mm (2.95 x 3.05 in.) Piston Ring End Gap - Installed (min) 0.25 mm (0.0098 in.) Piston Ring Groove Width (1st) 0.090-0.125 mm (0.0035-0.0049 in.) (2nd) 0.050-0.085 mm (0.0020-0.0033 in.) (3rd) 0.040-0.075 mm (0.0016-0.0030 in.) Piston Pin Bore (max) 18.025 mm (0.7096 in.) Piston Pin Outside Diameter (min) 17.996 mm (0.7085 in.) CAMSHAFT AND CYLINDER HEAD Camshaft Lobe Height (min) 29.498 mm (1.161 in.) (intake/exhaust) Camshaft Injection Lobe (min) 28.848 mm (1.136 in.) Camshaft Journal Holder Inside (max) 37.060 mm (1.459 in.) Diameter Camshaft Journal Diameter (min) 36.975 mm (1.456 in.) Cylinder Head Distortion (max) 0.10 mm (0.004 in.) Rocker Arm Bore 18.015-18.030 mm (0.7092-0.7098 in.) Rocker Arm Shaft 17.989-18.000 mm (0.7082-0.7087 in.) CRANKSHAFT Connecting Rod Piston Pin (max) 18.025 mm (0.7096 in.) Bushing (inside diameter) Crankshaft Main Bearing Journal 51.023-51.059 mm (2.0092.010 in.) Crankshaft Connecting Rod Journal(min) 39.9 mm (1.57 in.) Connecting Rod Clearance 0.021-0.066 mm (0.00080.0026 in.) Main Bearing Clearance 0.023-0.078 mm (0.00090.0031 in.) Rod Bearing Diameter 40.021-40.050 mm (1.57561.5767 in.) Oil Pump Pressure at 120° C (248° F) 1.1 kg/cm² (15.6 psi) @900 RPM (min) Cooling Fan Thermo-Switch (offon) 93° C (199° F) Operating Temperature (onoff) 87° C (189° F) Bore x Stroke
Torque Specifications STEERING COMPONENTS Part
Part Bolted To
Handlebar Cap Steering Post Steering Post Bearing Housing Frame Steering Post Bearing Flange Frame Tie Rod End Knuckle/Steering Post EXHAUST COMPONENTS Exhaust Pipe Exhaust Manifold Spark Arrester Muffler
BRAKE COMPONENTS Brake Disc*** Hub Brake Hose Caliper Brake Hose Master Cylinder Brake Hose Auxiliary Brake Cylinder Auxiliary Brake Pedal Lever Axle Caliper Holder Knuckle Auxiliary/Hydraulic Caliper**** Knuckle
Torque ft-lb N-m 20 27 20 27 20 27 30 41 14 19 48 5 in.-lb 15 20 20 20 25 20 20
19 27 27 27 34 27 27
ENGINE/TRANSMISSION
DRIVE TRAIN COMPONENTS Part Front Mounting Bracket Engine Mount (Upper)** Engine Mount (Front/Rear) Front Differential*** Rear Drive Gear Case Input Housing Output Drive Yoke Nut* Differential Housing Cover** Drive Bevel Gear Retaining Nut** Secondary Drive/Bevel Gear Shaft Pinion Housing Ring Gear/Thrust Button* Gear Case Cover Lock Collar Hub Nut Drain Plug
Part Bolted To Engine Frame Frame Frame/Differential Bracket Frame Gear Case Housing Output Shaft Differential Housing Secondary Output Shaft Transmission Case
Torque ft-lb N-m 20 27 35 48 20 27 38 52 38 52 23 31 72 98 23 31 87 118 80
108
Gear Case 25 34 Gear Case 8 11 Gear Case 23 31 Differential Housing 125 170 Shaft/Axle (min) 200 272 Front Differential/Rear Drive 42 5 in.-lb Fill Plug Front Differential/Rear Drive 16 22 Oil Drain Plug Engine 18 24 Wheel (Steel) Hub 45 61 Wheel (Aluminum) Hub 80 108 CHASSIS COMPONENTS Shift Lever*** Shift Axle 8 11 ELECTRICAL COMPONENTS Ground Wire Transmission 8 11 SUSPENSION COMPONENTS (Rear) A-Arm Frame 50 68 Shock Absorber (Upper) Frame 50 68 Shock Absorber (Lower) Lower A-Arm 20 27 Knuckle A-Arm 50 68 SUSPENSION COMPONENTS (Front) A-Arm Frame 50 68 Ball Joint Cap Screw Knuckle 35 48 Shock Absorber Frame 50 68 Shock Absorber Upper A-Arm 50 68
* w/Red Loctite #271 ** w/Green Loctite #609 *** w/Blue Loctite #243 **** “Patch-Lock”
Part Transmission Mounting Plate Connecting Rod Cap Main Bearing Cap Rocker Arm Support Cylinder Head Valve Cover Driven Pulley Nut** Drive Clutch Movable Drive Face* Oil Pump Output Shaft* Output Shaft Nut* Starter Flywheel/PTO Shaft Crankshaft Pulley Chamber Ring Nut
Part Bolted To Crankcase/Transmission
Glow Plug Crankshaft Pulley*** Timing Belt Idler Nut V-Belt Cover V-Belt Housing Fuel Rail
Connecting Rod (4 Steps) Engine Block (6 Steps) Cylinder Head Cylinder (5 Steps) Cylinder Head Fixed Face Flywheel/PTO Shaft Fixed Drive Hub Engine Block Output Shaft Coupler Output Shaft V-Belt Housing Crankshaft Timing Belt Drive Pulley Chamber (Step 1) (Step 2) Cylinder Head Crankshaft Engine Block V-Belt Housing Crankcase/Transmission Unit Injectors
Gear Case (Left) Oil Pan Oil Pan Cover Crankshaft Seal/Flange Camshaft Support Housing Fuel Injector Control Rack
Gear Case (Right) Crankcase Oil Pan Engine Block Cylinder Head Unit Injector
Unit Injector Retainer Nut Camshaft Drive Pulley Lift Pump Eccentric Water Pump
Cylinder Head (5 Steps) Camshaft Camshaft Engine Block
Torque ft-lb N-m 35 48 29 44 29 35 6.5 125 40 85 22 20 80 35 40 9 72 130 18 260 29 9 25 36 in.-lb 8 7 7 9 7 11 in.-lb 15 59 59 22
40 60 40 48 9 170 54 116 30 27 108 48 54 12 98 177 24 354 39 12 34 4 11 10 10 12 10 1.2 20 80 80 30
* w/Red Loctite #271 ** w/Green Loctite #609 *** w/Blue Loctite #243
3
Torque Conversions (ft-lb/N-m) ft-lb 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
N-m 1.4 2.7 4.1 5.4 6.8 8.2 9.5 10.9 12.2 13.6 15 16.3 17.7 19 20.4 21.8 23.1 24.5 25.8 27.2 28.6 29.9 31.3 32.6 34
ft-lb 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
N-m 35.4 36.7 38.1 39.4 40.8 42.2 43.5 44.9 46.2 47.6 49 50.3 51.7 53 54.4 55.8 57.1 58.5 59.8 61.2 62.6 63.9 65.3 66.6 68
ft-lb 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
N-m 69.4 70.7 72.1 73.4 74.8 76.2 77.5 78.9 80.2 81.6 83 84.3 85.7 87 88.4 89.8 91.1 92.5 93.8 95.2 96.6 97.9 99.3 100.6 102
ft-lb 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100
Fuel - Oil - Lubricant
N-m
NOTE: Arctic Cat recommends the use of genuine Arctic Cat lubricants.
103.4
RECOMMENDED FUEL
104.7
The recommended fuel to use is biodiesel blend up to 20% (B20), #1 or #2 diesel fuel (42-50 cetane), or JP 5 or JP 8 turbine fuel. At temperatures above -10° C (14° F), use #2 diesel fuel or a biodiesel blend up to 20%. At temperatures at or below -10° C (14° F), use #1 diesel fuel. Diesel fuel with a minimum cetane number below 42 should not be used.
106.1 107.4 108.8 110.2 111.5 112.9 114.2 115.6 117 118.3 119.7 121 122.4 123.8 125.1 126.5 127.8 129.2 130.6
CAUTION Never use biodiesel blends at temperatures at or below -10° C (14° F).
RECOMMENDED ENGINE OIL The recommended oil to use is an oil which is rated SJ/ CF under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat engine. The recommended engine oil viscosity is SAE 10W-40. Ambient temperature should determine the correct weight of oil. See the viscosity chart or an authorized Arctic Cat ATV dealer for details.
131.9 133.3 134.6 136
Break-In Procedure A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners. 4
OILCHARTE
CAUTION Any oil used in place of the recommended oil could cause serious engine damage.
RECOMMENDED TRANSMISSION LUBRICANT The recommended transmission lubricant is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the ATV transmission.
CAUTION Any lubricant used in place of the recommended lubricant could cause serious transmission damage.
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT
Preparation For Storage
The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives.
CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.
FILLING FUEL TANK ! WARNING Always fill the fuel tank in a well-ventilated area. Never add fuel to the ATV fuel tank near any open flames or with the engine running. DO NOT SMOKE while filling the fuel tank.
CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration.
Arctic Cat recommends the following procedure to prepare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Fill the fuel tank with fresh #1 or #2 diesel fuel (according to ambient temperatures); then add a quality anti-microbial additive. Run the engine in a well-ventilated area for several minutes to make sure fresh, treated fuel is circulated throughout the entire injection system.
CAUTION DO NOT store the ATV with biodiesel (B20) in the fuel system. Severe damage to the fuel system may occur.
4. Plug the exhaust hole in the muffler with a clean cloth. 5. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. ATV0049B
Since fuel expands as its temperature rises, the fuel tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold fuel and then moved to a warm area.
! WARNING Do not overflow fuel when filling the fuel tank. A fire hazard could materialize. Always allow the engine to cool before filling the fuel tank.
Tighten the fuel tank cap securely after filling the tank.
! WARNING Do not over-fill the fuel tank.
Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.
6. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications. 7. Fill the cooling system to the bottom of the stand pipe in the filler neck with properly mixed coolant. 8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 9. Store the ATV indoors in a level position.
CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.
Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV. 1. Clean the ATV thoroughly. 2. Clean the engine. Remove the cloth from the muffler. 5
3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 4. Change the engine oil and filter. 5. Check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables.
CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the electrical system.
6
CAUTION Connect the positive battery cable first; then the negative.
7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind.
It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference.
Periodic Maintenance/ Tune-Up
A. Throttle Lever Pivot/Cable Ends B. Brake Lever Pivot/Cable Ends
Tighten all nuts, cap screws, screws, and bolts. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, screws, and bolts are tightened to specifications.
C. Auxiliary Brake Cable Ends
A = Adjust C = Clean I = Inspect
Periodic Maintenance Chart
Item Battery Fuses/Relays/PDM Air Filter Valve Clearance Muffler/Spark Arrester Fuel/Vent Hoses Fuel Injectors Throttle Cable Engine Oil Level Engine Oil/Filter Front Differential/Rear Drive Lubricant Transmission Lubricant Tires/Air Pressure Steering Components V-Belt Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) Nuts/Cap Screws/Screws/Bolts Injector Timing Headlight/Taillight-Brakelight Switches Shift Lever Handlebar Grips Handlebars Gauges/Indicators Frame/Welds/Racks Electrical Connections Complete Brake System (Hydraulic & Auxiliary) Brake Pads Brake Fluid Brake Hoses Coolant/Cooling System Timing Belt Alternator Belt
Initial Service After Break-In (First Month or 100 Miles) I I I
Every Month or Every 100 Miles I
Every 3 Months or Every 300 Miles
L = Lubricate R = Replace
Every 6 Every 2 Months or Every Year or Years or Every 1250 Every 500 Every 5000 Miles Miles Miles
As Needed
R
C R R A R
I I C
I
R I
I
C-L Replace after initial 300 miles.
I I I I I I
R
I I l l*
I
I
A A R R A-L R R R
I I I I I I I
I
I I I I I
A A-R I R R (4 Yrs) R (4 Yrs) R R R R
l l
C L-R
C
R R I Replace coolant every 2 years.
R (4 Yrs) R
I
I
* Service/Inspect more frequently when operating in adverse conditions.
7
3. Clean dust and debris from the air filter housing; then remove the cotton-fabric safety element using care not to allow dirt and debris to enter the engine.
Air Filter CLEANING AND INSPECTING FILTER CAUTION Failure to inspect the air filter frequently if the vehicle is used in dusty, wet, or muddy conditions can damage the engine.
NOTE: This ATV is equipped with a dry-paper air filter and a cotton-fabric safety element.
DE008
4. Lightly tap the dry-paper air filter to dislodge the dirt and dust. Do not use compressed air. 5. Insert a suitable light into the dry-paper air filter and look for any “pin-points” of light shining out of the filter medium. A bright “pin-point” of light indicates a hole and the filter element must be replaced.
DE014A
1. Open the air filter access cover and remove the operator’s seat; then rotate the air filter housing cover counterclockwise and remove from the filter housing.
DE028A
CAUTION A torn air filter can cause damage to the engine. Dirt and dust may enter the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn. DE006A
2. Remove the dry-paper air filter. Do not remove the cotton-fabric safety element at this time.
6. Check the safety element for signs of dirt build-up. If dirt is present on the element, it indicates a leak or hole in the dry-paper air filter element and both elements must be replaced. 7. Install the safety element; then install the dry-paper air filter. 8. Check the drain valve in the air filter housing cover for dirt, deterioration, or poor sealing. Clean or replace as required.
DE007
8
DE015
CF105A
9. Install the air filter housing cover (drain facing downward) and lock it in place by turning clockwise.
2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen. ď ŽNOTE: If the screen or gasket is damaged in any way, it must be replaced.
3. Install the spark arrester assembly with gasket; then secure with three cap screws. Tighten to 48 in.-lb.
Adjusting Throttle Cable To adjust the throttle cable free-play, follow this procedure. DE006A
1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster.
Valve Clearance To check/adjust valve clearance, see Top-Side Components in Engine/Transmission.
Muffler/Spark Arrester The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure.
! WARNING
AL611D
2. Turn the adjuster until the throttle cable has proper free-play of 1/4 in. at the lever.
Wait until the muffler cools to avoid burns.
1. Remove the three cap screws securing the spark arrester assembly to the muffler; then loosen and remove the arrester.
ATV-0047C
3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. 9
Engine RPM (Idle) NOTE: The idle RPM is not adjustable on the 700 Diesel.
Engine Oil - Filter Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain easily and completely. 1. Park the ATV on level ground. 2. Remove the engine oil filler cap.
DE018
NOTE: Install a new O-ring each time the filter is replaced.
7. Install the engine drain plug and tighten to 18 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil filler cap.
CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use racing, vegetable, non-detergent, and castor-based oils.
8. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes. 9. Turn the engine off and wait approximately three minutes. DE025A
3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.
10. Remove the oil level stick and wipe it with a clean cloth.
DE519D
11. Install the oil level stick and push in firmly. DE017A
4. Remove the right-side engine cover. 5. Using a suitable filter wrench, remove the oil filter. NOTE: Clean up any excess oil after removing the filter.
6. Apply oil to a new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten until contact is made; then tighten an additional 3/4 turn.
10
12. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark.
CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the “L” mark but not higher than the “F” mark.
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4. Install the drain plug and tighten securely. Pour recommended lubricant into the filler hole. Install the filler plug. 5. Remove the transmission lubricant level stick and wipe it with a clean cloth; then check the lubricant level with the level stick.
DE024A
13. Inspect the area around the drain plug and oil filter for leaks. 14. Install the right-side engine cover.
Transmission Lubricant Check and change the transmission lubricant according to the Maintenance Schedule. When adding or changing the lubricant, use approved SAE 80W-90 hypoid and use the following procedure. 1. Place the ATV on level ground. 2. Remove the transmission fill plug. Make sure not to allow contaminants to enter the opening.
DE002A
Front Differential/Rear Drive Lubricant Check and change the lubricant according to the Periodic Maintenance Chart. When adding or changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the level plug; the lubricant level should be visible at the threads. If low, add SAE approved 80W-90 hypoid gear lube as necessary. To change the lubricant, use the following procedure. 1. Place the ATV on level ground. 2. Remove each filler plug. 3. Drain the lubricant into a drain pan by removing in turn the drain plug from each.
DE026A
3. Remove the transmission drain plug from the bottom of the transmission and drain the lubricant into a drain pan.
CF107B
DE016A
11
Lights Each time the ATV is used, lights should be checked for proper function. Rotate the ignition switch to the lights position; the headlights and taillight should illuminate. Test the brakelight by compressing the brake lever. The brakelight should illuminate.
HEADLIGHT CF106C
4. After all the lubricant has been drained, install the drain plugs and tighten to 42 in.-lb. 5. Pour the appropriate amount of recommended lubricant into each filler hole. 6. Install the fill plugs. Tighten to 16 ft-lb. NOTE: If the differential/rear drive lubricant is contaminated with water, inspect the drain plug and filler plug.
Tires TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed in General Specifications. Do not under any circumstances substitute tires of a different type or size.
! WARNING Always use the size and type of tires specified. Always maintain proper tire inflation pressure.
TIRE INFLATION PRESSURE
NOTE: The bulb portion of the headlight is fragile. HANDLE WITH CARE. When replacing the headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.
! WARNING Do not attempt to remove the bulb when it is hot. Severe burns may result.
To replace the headlight bulb, use the following procedure. 1. Remove the wiring harness connector from the back of the headlight. 2. Grasp the bulb housing, turn it counterclockwise, and remove the bulb. 3. Install the new bulb into the housing and rotate it completely clockwise. 4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket counterclockwise and remove from the housing.
Front and rear tire inflation pressure should be 0.35 kgcm² (5.0 psi).
Driveshaft/Coupling The following drive system components should be inspected periodically to ensure proper operation. A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. CF135A
Injector Timing To check/adjust injector timing, see Top-Side Components in Engine/Transmission.
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2. Pull the bulb straight out of the socket; then insert a new bulb.
CF132A
3. Insert the socket into the housing and turn it clockwise to secure.
CHECKING/ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.
CD714A
Shift Lever CHECKING ADJUSTMENT
1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface). ď ŽNOTE: There should be an average operating load on the ATV when adjusting the headlight aim.
2. Measure the distance from the floor to the mid-point of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. 4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface.
CF130B
Stop the ATV completely and shift the transmission into the R position. The reverse gear indicator light should be illuminated.
! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop suddenly throwing the operator from the ATV.
If the reverse light does not illuminate when shifted to the reverse position, the switch may be faulty, the fuse may be blown, the bulb may be faulty, a connection may be loose or corroded, or the lever may need adjusting. To adjust, proceed to Adjusting Shift Lever.
ADJUSTING SHIFT LEVER 1. Place the shift lever in the R position; then remove the seat and left-side engine cover.
ATV-0070C
2. With the ignition switch in the ON position, loosen jam nut (A) (left-hand threads); then loosen jam nut (C) and with the shift lever in the reverse position, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD.
7. Adjust each headlight by turning the adjuster knob clockwise to raise the beam or counterclockwise to lower the beam.
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CF258A
AL681
3. Tighten the jam nuts securely; then shift the transmission to each position and verify correct adjustment.
2. Compress the brake lever/pedal several times to check for a firm brake. If the brake is not firm, the system must be bled. To bleed the main brake system, use the following procedure.
ď ŽNOTE: An E (Error) in the gear position icon indicates no signal or a poor ground wire connection in the circuit. Troubleshoot the harness connectors, gear shift position connector, gear shift position switch, and LCD connector.
4. Install the seat and left-side engine cover.
Frame/Welds/Racks The frame, welds, and racks should be checked periodically for damage, bends, cracks, deterioration, broken components, and missing components. If replacement or repair constitutes removal, see Steering/Frame.
A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid; then install and secure the cover. B. Slowly compress the brake lever several times. C. Remove the protective cap, install one end of a clear hose onto one FRONT bleeder screw, and direct the other end into a container; then while holding slight pressure on the brake lever, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake lever. Repeat this procedure until no air bubbles are present.
Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake system, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir. If the level in the reservoir is not visible in the sight glass, add DOT 4 brake fluid.
AF637D
PR377C
738-420A
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